Automated Finite Element Modeling of Staggered Composites: Software Framework, Verification, and Architectural Effects

Abstract

This study presents a parametric Python framework to automate two-dimensional finite element model generation of staggered brick-and-matrix composites in Abaqus/Standard. The suite includes four standalone scripts---for periodic and finite-gauge tensile models, double-cantilever beam (DCB), and three-point end-notched flexure (3ENF) specimens---with three complementary plug-ins that generate editable, native Abaqus/CAE databases. User-defined parameters govern key geometric variables (brick length, ply count, layer offset), material assignments, cohesive interfaces, precracks, boundary conditions, and mesh discretization, facilitating systematic architectural evaluations. To ensure numerical robustness, an analysis of potential numerical artifacts, mesh sensitivity, and the validity of an RVE representation within a highly non-linear regime was conducted. Given the mesh dependency of Hashin damage evolution, several postprocessing criteria based on damage initiation were evaluated alongside published experimental data to determine the optimal mesh size. Using this calibrated setup, the framework was deployed to analyze the mechanical effects of brick length and layer offset. Architectural comparisons showed that aligned matrix pockets produced the lowest tensile stiffness and load capacity, while a quarter-pitch offset achieved the highest tensile stiffness and strength among non-aligned configurations. Interestingly, the best-performing tensile configuration did not provide the best fracture performance, revealing a fundamental trade-off between tensile and fracture resistance.